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Raypak HI DELTA 122-322 User's Manual

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1. BOILER B I ol 2 2 2 7 2 Fig 9390 NATURALDRAFT VERTICAL VENT CERTIFIED MINIMUM MMM iiia CATEGORY VENTING RECOMMENDED BAROMETRIC DAMPER MATERIAL VENT SIZE INCHES FEET Type B or Equivalent NOTE Vent lengths are based on a lateral length of 2 feet Refer to the latest edition of the NFGC for further details ANSI Z223 1 28 Natural Draft Vertical Venting System 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 negative draft must be within the range of 01 to 08 W C as measured 12 in from the appliance flue outlet to ensure proper operation Vent material must be listed by a nationally recognized test agency The maximum and minimum venting length for Category I appliance shall be determined per the latest edition of the NFGC U S or B149 1 and 2 Installation Code Canada The diameter of vent flue pipe should be sized according to Part 11 of the latest edition of the NFGC U S and part 7 and appendix B of the B149 1 and 2 Installation Code Canada The minimum flue pipe diameter for conventional negative draft venting using double wall B type vent is 4 for 122 5 for 162 202 and 242 6 for 322 NOTICE Vent Adapter will have to be used to connect B vent to the unit The connection from the appliance vent to the stack must b
2. The vertical direct vent cap is designed for roof top mounting only The air inlet opening MUST be installed one 1 foot above the roof line or above normal snow levels that might obstruct 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 aminimum 3 foot clearance from the air inlet opening 36 SECTION J 5 Outdoor Installation Outdoor models are self venting when installed with the factory supplied restricted direct vent cap and require no additional vent piping This special vent cap is provided with the heater in accordance with CSA requirements It must be installed directly on the heater See Section B for correct clearances Care must be taken when locating the outdoor unit because the flue gases discharged from the vent hood can condense as they leave the hood Improper location can result in damage to adjacent structures or building finish For maximum efficiency and safety the following precautions must be observed a b c d e f g Outdoor models must be installed outdoors and must use the outdoor vent hood supplied by the manufacturer 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. Horizontal Thru Wall Venting Category III INSULATED EXHAUST VENTING P M HORIZONTAL THRU WALL VENTING CATEGORY IIT TABLE APPLIANCE CATEGORY CERTIFIED VENTING MATERIAL Stainless Steel Gas Tight Horizontal Thru wall Venting System Category IIT Installation 12 MN FLUE EXHAUST VENT CAP 12 MIN Fig 9402 MAXIMUM VENTING LENGTH VENT SIZE INCHES Subtract 10 ft per elbow Maximum three elbows 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 outdoors Adequate combustion and ventilation air must be supplied to the mechanical room in accordance with the NFGC or in Canada the B149 1 and 2 Installation Code 31 The total length of the horizontal thru wall exhaust vent system should not exceed seventy 70 feet in length Ifhorizontal run exceeds 70 feet an appropriately sized extractor must be used To maintain proper operation pressure reading must be between 01 to 08 W C as measured 12 in from the appliance flue outlet Each elbow used is equal to ten 10 feet of straight pipe This will allow installation in one of the four following combinations 70 of straight flue pipe 60 of straight flue pipe and one elbow 50 of straight flue pipe and two elbow
4. ot sa 2 O3TIVISNI sed 31naoN NOLLINOI op ve DU n Ej HOLIMS 3HnSS3Hd 35v1S 191 z B 3ovis PUZ T 3 S 1 182 13539 TINA HOIWS 8 9 LIAFI IH L1INI1 IH LN3A D L L C Bl r E HOLIMS 13555 9 9 Aa g HOLIMS 5 9 1531 gt 13000 qiia ASo12v4 vivd dnd n TWNOILdO Ov9SZSLIN JequinN cc amp ccy STAGOW O o NOSN3S 3SNOdS34 1SV3 38084 41 SECTION L GENERAL SAFETY PRECAUTIONS To meet commercial water use needs the temperature Hi Limt on this hot water heater is adjustable up to 210 F However water temperatures over 125 F can cause severe burns instantly or death from scalds The preferred starting point for setting the control for supplying general purpose hot water is 125 F Safety and energy conservation are factors to be considered when setting the water temperature on the thermostat The most energy efficient operation will result when the temperature setting is the lowest that satisfies the needs consistent with the application D A N G E R Water temperature over 125 F can cause seve
5. 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 or operating at heater temperatures exceeding 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 SUCHAS 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 fl
6. GREEN GROUND Fig 9237 AC 108 Volts AC Minimum 132 Volts AC MAX AB 108 Volts AC Minimum 132 Volts AC MAX BC lt VoltAC 21 MAKING THE ELECTRICAL CONNECTIONS Refer to Fig 9403 Wiring Connection and Wiring Diagram 152564 1 2 7 Verify circuit breaker is properly sized by referring to heater rating plate A dedicated circuit breaker should be provided Turn off all power to the heater Verify that power has been turned off by testing with a volt ohm meter prior to working with any electrical connections or components Observe proper wire colors while making electrical connections Many electronic controls are polarity sensitive Components damaged by improper electrical installation are not covered by warranty Provide an external surge suppressor capable of maintaining system integrity Provide overload protection and a disconnect means for equipment serviceability as required by local and state code Install heater controls thermostats or building management systems in accordance with the applicable manufacturer s instructions Conduit should not be used as the ground There must be a solidly wired ground NOTICE A grounding electrode conductor shall be used to connect the equipment grounding conductors the equipment enclosures and the grounded service conductor to the grounding electrode FIELD WIRING CONNECTION FIELD CONNECTED CONTROLLERS MODELS 122 322 STAGE STAGE 1 2 IF
7. hoods and bathroom exhausts so they will operate at maximum speed Do not operate summer exhaust fan Close fireplace dampers Place in operation the appliances being inspected Follow the manufacturers instructions for lighting each appli ance Adjust thermostat so appliance will operate continuously Test for spillage at the drafthood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe toilet paper trick For the Hi Delta check the pressure at a pressure tap located 12 in above the bottom joint of the first vertical vent pipe Pressure should be anywhere between 01 to 08 inch W C After it has been determined that each appliance remaining connected to the common venting system 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 Any improper operation of the common venting system should be corrected so that the installation conforms with the latest edition of the NFGC US and the B 149 1 and 2 Installation Code 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 Appendix G in the NFGC US and Appendix B of the B 149 Installation Code Canada 30 SECTION J 2 COMBUSTION AIR FILTER BOILER B NE
8. 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 19 AT GPM AP MPs SHL AT GPM MPS SHL AT GPM AP MPs SHL 122 10 20 25 114 49 8 26 40 1141 78 7 30 53 1 74 103 162 14 20 25 114 49 11 26 41 114 79 9 30 54 1 1 4 104 20 26 1 1 4 50 13 26 42 114 80 9 44 118 112 16 1 322 27 20 27 1112136 20 27 48 12 2 66 12 44 122 112 165 GAS PRESSURE REGULATOR The gas valve pressure regulator s on the heater are nominally preset at 3 5 W C for Natural gas and 10 5 W C for Propane gas manifold pressure The pressure at the gas valve outlet tap measured with a manometer while in operation should be 3 5 0 1 W C for Natural gas and 10 5 0 1 W C for Propane gas If an adjustment is needed turn the adjustment screw clockwise to increase pressure or counter clockwise to decrease pressure 20 SECTION I ELECTRICAL POWER CONNECTIONS Installations must follow these codes National Electrical Code and any other national state provincial or local codes or regulations having jurisdiction Safety wiring must be N E C Class 1 Heater must be electrically grounded as required by N E C In Canada C22 1 The heater is wired for 120 Volts 12 AMPS T
9. 007141F 007141F 007141F 007141F Adj Auto Hi Limit 200 Deg Max WH 006445F 006445F 006445F 006445F 006445F Manual Hi Limit Non Adjustible 36T 240 Deg H 008520F 008520F 008520F 008520F 008520F Manual Hi Limit Non Adjustible 36T 2 Deg WH 008093F 008093F 008093F 008093F 008093F Electronic Fast Response Sensor w Probe 240 Deg H 008521F 008521F 008521F 008521F 008521F Electronic Fast Response Sensor w Probe 200 deg WH 005555F 005555F 005555F 005555F 005555F Probe Fast Response 006532F 006532F 006532F 006532F 006532F PC Control Board 240 Deg H 008540F 008540F 008540F 008540F 008540F PC Control Board 200 Deg WH 005197F 005197F 005197F 005197F 005197F Remote Aquastat Tankstat B 2 007148F 007148F 007148F 007148F 007148F Remote Aquastat Tankstat 2 Stage B 3 007392F 007392F 007392F 007392F 007392F Controller 2 Stage B 4 007393F 007393F 007393F 007393F 007393F Controller 4 Stage B 20 006445F 006445F 006445F 006445F 006445F Flow Switch 007142F 007142F 007142F 007142F 007142F Switch Air Pressure N C 006538F 006538F 006538F 006538F 006538F m Switch Air Pressure N O 008827F 008827F 008756F 008756F 008756F 008470F 008471F GAS VALVES Combination Gas Valve On Off Nat 3 4 007424F 007424F 007424F 007424F 007424F Combination Gas Valve On Off Pro 3 4 007425F 007425F 007425F 007425F 007425F Solenoid Gas Valve 008407F 008407F 008407F 008407F 008407F HEAT EXCHANGER Heat Exch Cast Iron Side Connections 008408F 008409F 008410F 008411F 008412F Heat Exch Brass Side C
10. CIBF Medium 008708 008708 008708 005593 008746 Pump Inline CIBF Hard 008711 008711 008711 008716 008716 Pump Cartridge 0010 951154F 951154F 951154F 951154F 951154F Pump Cartridge 0012 N A N A N A N A 951153F Pump Flange Gasket 0012 008747F 008747F 008747F 008747F 008747F RTV Sealant 10 oz 005755F 005755F 005755F 005755F 005755F FiberFrax Strip Insulation 1 Wide 008473F 008473F 008473F 008473F 008473F Sight Window Plug 008474F 008474F 008474F 008474F 008474F Window Combustion Chamber 006947F 006947F 006947F 006947F 006947F Flame Sensor 006535F 006535F 006535F 006535F 006535F 007400F 007400F 007400F 007400F 007400F OPTIONS Remote Sensor for Low Water Cut Off 008063F 008063F 008063F 008063F 008063F Low Water Cut Off PC Board 007157F 007157F 007157F 007157F 007157F Reset Test Switch for Low Water Cut Off 005641F 005641F 005641F 005641F 005641F REFRACTORY Refractory Kit All Panels 008475F 008476F 008477F 008478F 008479F Refractory Front Panel 008480F 008481F 008482F 008483F 008484F SHEETMETAL Jacket Top 008485F 008486F 008487F 008488F 008489F Jacket Top w Top Water Connections 008530F 008531F 008532F N A N A Door Assy 008490F 008491F 008492F 008493F 008494F Door Assy wl Top Gas Connections 008534F 008535F 008536F N A N A Rear Jacket Panel N A 008495F 008496F 008497F 008498F Left Side Jacket Panel 008499F 008499F 008499F 008499F 008499F Right Side Jacket Panel 008500F 008500F 008500F 008500F 008500F Front Combustion Chamber Panel 008501F 0085
11. COMBUSTION AIR SUPPLY FOR U S INSTALLATION ONLY a All Air from Inside the Building The confined space shall be provided with two permanent openings communicating directly with an additional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination Each opening shall have a minimum free area of 1 square inch per 1 000 Btu per hour 22 cm per kW of the total input rating of all gas utilization equipment in the confined space but not less than 100 in 645 cm One opening shall commence within 12 in 30 cm of the top and one opening shall commence within 12 in 30 cm of the bottom of the enclosure The minimum dimension of air openings shall be not less than 3 in 8 cm in any direction b Air from Outdoors The confined space shall communicate with the outdoors in accordance with methods 1 or 2 The minimum dimension of air openings shall not be less than 3 in 8 cm in any direction Where ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect 1 Two permanent openings one commencing within 12in 30 cm of the top and one commencing within 121 30 cm of the bottom of the enclosure shall be provided The openings shall communicate directly or by ducts with the outdoors or s
12. Check with Manufacturer for proper paddle size Utilize correct paddle size for proper operation Flow switch will not operate if flow is less than 20 GPM s Fig J 4 FLOW SWITCH OPERATING CONTROL lt The heater may be equipped with different types of operating controls Consult data sheet supplied with installation instructions See Section L for adjustment safety precautions on domestic hot water applications Drw 8643 Ns THERMOSTAT CONTROL 39 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 probe A 3 second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets 40 Drw 8996 1 LOW WATER CUT OFF Fig 1 5 LVLSOWYSHL AINO 0 50 ONIMIM JOV 14484 NMOHS SV Q30lAOMd STOMINOO 63 3LVNIA331 Tv 100 4901 NI LINSSY AYN NadONd 01 3HfllIv4 NOILOSNNOD ANNONS ISN SALON NOWWOS LOH da 39018 IWNINMSL 5 XB N SV9 u E a LOWS 9 3A IVA SV9 ug 0103105
13. System Head Loss Ft MPS Minimum Pipe Size NPT System head loss is based on the heater and tank placed no more than 5 feet apart and 25 feet equivalent length of pipe and fittings 16 SINGLE HEATER DOMESTIC HOT WATER WITH ONE STORAGE TANK MINIMUM PIPE SIZES CATALOG NO 122 202 1 1 4 242 322 1 1 2 REPLACING HOT WATER SUPPLY A x T amp P RELIEF VALVE HEATER MOUNTED PRESSURE RELIEF VALVE A THERMOMETER EXPANSION TANK A TANKSTAT MAIN RECIRCULATION PUMP Z BY OTHERS EN RECIRCULATION ACAD 8337 DWG ET BOLERS SHOWN S LIST 4 NOTES REPRESENT VARIOUS MODELS BECAUSE 1 PLUMB SWING CHECK VALVE IN GRAVITY CLOSED POSITION E PRESSURE wa ais i INDIVIDUAL MODELS RELIEF VALV PIPE ALL RELIEF VALVES TO DRAIN OR AS LOCAL CODES REQUIRE WILL VARY IN DESICN SIZING SEE EACH CIFIC BOILER TYPE PUMP INSTALL COLD WATER BETWEEN HEATER OUTLET AND TANK gt DETAILS 5 LOCATE TEE AS CLOSE AS POSSIBLE TO TANK 5 SEE CHART MINIMUM PIPE SIZES FOR MINIMUM PIPE SIZES UNION 8 ZING BASED ON HEATER AND TANK BEING PLACED FIVE FEET PART IF DISTANCE IS GREATER THE PUMP MUST BE SIZED TO CCOMMODATE INCREASE IN PIPING RELATED LOSSES CATE VAI DATE VALVE ROVIDE FOR THERMAL EXPANSION OF HOT WATER IF A BACKFLOW REVENTER CHECK VALVE WATER METER OR PRESSURE EDUCING VALVE S INSTALLED IN THE COLD WATER LINE CHECK VALVE GUARANTEED 80 DRAW WITH MPERATURE DROP RAYP
14. connect more than one heater to a common 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 vent be less than the area of the largest heater exhaust outlet 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 vent or better 29 Common venting systems may be too large when an existing unit is removed At the time ofremoval ofan existing appliance the following steps must be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a b c d g Seal any unused opening in the common venting system Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion or other unsafe condition Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common vent system Turn on any exhaust fans such as range
15. 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 This heater complies with the latest edition of ASHRAE 90 1 Standard Altering any RAYPAK pressure vessel by installing replacement heat exchangers tube bundle headers or any other ASME part not manufactured and or approved by RAYPAK will instantly void the ASME ratings of the vessel and any RAYPAK warranty on the vessel This also violates national state and local approval codes Rated inputs are suitable for up to 4500 feet elevation without de rate Consult the Factory for installations at altitudes in excess of 4500 feet INTAKE HIDELTA COMPONENT LOCATION COMBUSTION AIR FLUE EXHAUST lt BACK PRESSURE RELIEF CONNECTION E NN WATER OUTLET GAS CONNECTION WATER INLET VIEW PORT LEFT SIDE AIR INTAKE AIR INTAKE ADJUSTMENT FILTER BOX See detail page 7 FLUE EXHAUST TUBE BLOWER AIR CHAMBER SWITCH COMBUSTION AIR SWITCH TUBE BUNDLE ASSY GAS VALVE H See detail page 7 5 r8 ede LWCO TEST SWITCH MEC P P LWCO RESET SWITCH LWCO PCB HI LIMITS LJ FLAME SENSOR SONRAS Eg dus IGNITER 2nd STAGE VALVE BURNERS GAS TRAIN 6 FRONT General Information BASIC DATA Second valve located inside a
16. is installed and or adjust the service regulator 44 3 0 3 1 1 2 3 4 WNP START UP Blower Adjustment Disconnect fan pressure switch tubing at plenum and connect manometer using a tee Close all manual firing valves Turn power on Check manometers attached to fan pressure switch The readings should be 5 1 W C for models 102 and 122 7 1 W C for models 202 242 322 If not adjust the air shutter on the blower to attain the correct value See air shutter adjustment page 7 Turn power off Reconnect fan pressure switch tubing to original position Main Burner Adjustment Turn off unit Open manual firing valve Turn on the unit wait 15 seconds and the igniter should glow Sight glass to check igniter at both ends of the heater Gas valve should be open after 45 seconds If burner does not light on first trial It will retry up to 3 times Main burner ignition check manifold gas pressure at gas valve manifold pressure tap See gas valve detail page 7 This should read 3 5 1 W C for natural gas or 10 5 1 for LP gas If the pressure reading differs by more than 1 W C Remove manifold adjustment screw cover off the pressure regulator on the gas valve adjust main burner manifold pressure Replace the manifold adjustment screw cap on the gas valve Your Hi Delta is tuned in 3 3 Safety Inspection Replace main gas manifold adjustment screw cap C
17. latest edition of the NFGC U S and B149 1 and 2 Installation Code Canada The connection from the appliance exhaust vent to the stack must be as direct as possible and should be the same as or larger than the vent outlet The vent must be installed to prevent accumulation of condensate and where necessary have means provided for drainage of condensate 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 clearances and to prevent physical damage or separation of joints Vertical Direct Vent Termination The exhaust vent terminal should be vertical and should terminate outside the building at least two 2 feet above the highest point of the roof within 10 feet The vent cap should have a minimum clearance of four 4 feet horizontally from and in no case above or below unless a four 4 foot 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 consistent with the NFGC or in Canada the B149 1 and 2 Installation Code Gas vents supported only by flashing and extended above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads
18. or deck is greater than 1 ft 30 Venting Installation Tips Support piping horizontal runs at least every five 5 feet vertical runs use braces under or near elbows Follow items listed below to avoid personal injury or property damage Cut nonmetallic intake pipe with fine toothed hacksaw Do not use nonmetallic intake pipe or fittings that are cracked or damaged Do not use nonmetallic intake fittings if they are cut or altered Do not drill holes or use screws or rivets in nonmetallic intake pipe or fittings To make metallic vent joints Do not install seams of vent pipe on bottom of runs 100 Seal all joints and seams with high temperature silicone sealant VI Examine the venting system at least once year Check all joints and vent pipe connections for tightness corrosion or deterioration NOTE The words Flue Exhaust Flue and Exhaust Vent are used interchangeably VENTING CONFIGURATIONS For heaters connected to gas vents or chimneys vent installations shall be in accordance with the section on Venting of Equipment of the latest edition of NFGC or in Canada B149 1 and 2 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of local building codes 27 SECTION J 1 Natural Draft Vertical Venting Category D 10 FEET OR LESS VENT CAP 2 MIN i 2 MIN VENT PIPE SR COMBUSTION AIR FILTER
19. source To reduce the risk of electric shock disconnect all such connections before servicing Risk of electric shock More than one 1 disconnect switch may be required to de energize the equipment before servicing 38 IGNITION CONTROL MODULE The interrupted proved ignition device conserves energy When additional heat Is needed the combustion air blower starts to purge all air from the combustion chamber for about 15 seconds On proof of air flow the air proving switch closes and the igniter is energized eliminating the fuel costs of maintaining a constant pilot To assure safe operation the gas valve cannot open until the pilot igniter is verified The 100 igniter safety is an electronic device which closes the main gas valve within 8 10 of a second whenever the flame is interrupted Main burner is automatically lit when the device is powered and pre purged Unit performs its own safety check and opens the main valve only after the igniter is proven to be Fig 3322 capable of ignition IGNITION MODULE HIGH LIMIT MANUAL RESET lt The heater is equipped with a manual high limit temperature device Push the reset button and adjust the setting to 30 F or 40 F above desired operating temperature Drw 8644 J Fig J 3 MANUAL RESET HIGH LIMIT FLOW SWITCH Dual purpose control shuts off heater in case of pump failure or low water flow Mounted and wired in series with the main gas valve
20. three 3 feet from the top of the heater Three 3 sides must be open in the area under the overhang Roof water drainage must be diverted away from heaters installed under overhangs TABLE 2 OUTDOOR INSTALLATION MINIMUM CLEARANCES Heater Model Heater Side 120 322 Rear 12 Right 36 Left 36 Top Unobstructed Vent N A These clearances required where the outdoor vent cap is used If installing the heater outdoors with a vent stack the indoor clearances may be used T2 La Fig 9400 FRONT VIEW SIDE VIEW 10 SECTION C COMBUSTION AND VENTILATION AIR COMBUSTIONAND VENTILATIONAIR 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 supplied via conventional venting where combustion air is drawn from the area immedi ately surrounding the heater or via direct vent where combustion air is drawn directly from outside All installations must comply with the requirements of NFGC U S B 149 1 and 2 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 appendix A DIRECT COMBUSTION AIR If outside air is drawn through the intake pipe directly to the unit for combustion 1 Install combustion air direct vent in accordance with Section J of this manual CONVENTIONAL
21. vapors 2 Heater should never be covered or have any blockage to the flow of fresh air to the heater Risk of electrical shock More than one 1 disconnect switch may be required to de energize the equipment before servicing e UH Operation of this heater on low temperature systems requires special piping to insure correct operation e 1 this heater is to be installed above radiation level it must be provided with a low water cut off device at the time of heater installation UH This heater requires forced water circulation when the burner is operating See minimum and maximum flow rates Severe damage will occur if the heater is operated without proper water flow circulation CALIFORNIA PROPOSITION 65 WARNING This product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm Pay attention to these terms DANGER indicates the presence of immediate hazards which will cause severe personal injury death or substantial property damage if ignored I C indicates the presence of hazards or unsafe practices which could cause severe personal injury death or substantial property damage if ignored CAUTION indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored NOTICE indicates special instructions on installation operation or maintenance which are important
22. 02F 008503F 008504F 008505F Rear Combustion Chamber Panel 008506F 008507F 008508F 008509F 008510F Blower Air Intake Adapter 008511F 008511F 008511F 008511F 008511F Flue Collector Top 008512F 008513F 008514F 008515F 008516F Access Panel Ignitor Flame Sensor 008678F 008678F 008678F 008678F 008678F Access Panel Left Side Water Connections 008517F 008517F 008517F 008517F 008517F Access Panel Right Side Water Connections 008518F 008518F 008518F 008518F 008518F Access Panel Top Water Connections 008519F 008519F 008519F N A N A Seal Brackets 008700F 008700F 008700F 008700F 008700F VENTING Intake Filter Box Mounted 008555F 008555F 008555F 008555F 008555F Filter 008556F 008556F 008556F 008556F 008556F Inline Intake Air Filter Box 008699 008699 008699 008699 008699 Filter 008557F 008557F 008557F 008557F 008557F Outdoor Stack 008537 008538 008538 008538 008856 53 e pi LIMITED PARTS WARRANTY COMMERCIAL HEATERS TYPE HI DELTA MODELS 122 TO 322 MODELS HAND WH 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 WARRANT Y Domestic Hot Water Five
23. 09824F 009824F 009824F Ignition Control 008472F 008472F 008472F 008472F 008472F Transformer 100VA 007494F 007494F 007494F 007494F 007494F Pump Relay 007925F 007925F 007925F 007925F 007925F Pump Relay P C Board 004675F 004675F 004675F 004675F 004675F Blower Capacitor 008552F 008552F 008552F 008552F 008552F Terminal Block 3 Space 008523F 008523F 008523F 008523F 008523F Terminal Block 7 Space 007385F 007385F 007385F 007385F 007385F On Off Switch 008681F 008681F 008681F 008681F 008681F FOR ALTITUDES ABOVE 4 500 FEET CONSULT THE FACTORY 52 CALL OUT DESCRIPTION 322 M MISCELLANEOUS Flow Switch Paddle 004079F 004079F 004079F 004079F 004079F PRV 30 PSI 007470F 007470F 007470F 007470F 007470F PRV 45 PSI 007220F 007220F 007220F 007220F 007220F PRV 60 PSI 007222F 007222F 007222F 007222F 007222F PRV 75 PSI 007223F 007223F 007223F 007223F 007223F PRV 125 PSI 008091F 007224F 007224F 007224F 007224F PRV 150 PSI 007225F 007225F 007225F 007225F 007225F 052871F 052871F 052871F 052871F 052871F H 007205F 007205F 007205F 007205F 007205F W 007399F 007399F 007399F 007399F 007399F Pump Inline Top WaterCIBF 008708 008708 008708 N A N A Pump Inline Top Water BR Non Ferrous Waterway 008709 008709 008709 N A N A Pump Inline BR Soft 008709 008709 008709 008710 008710 Pump Inline BR Medium 008709 008709 008709 008710 008745 Pump Inline BR Hard 008713 008713 008713 008717 008717 Pump Inline CIBF Soft 008708 008708 008708 005593 005593 Pump Inline
24. AK BOILER TANK SIZING E AND HOOK UP DATA PIPING UN TEMP THERMOMETER 1 VERTICAL TA BOILER TYPE WH BALL VALVE 17 SECTION G POOL HEATING 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 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 that blends outlet water with the inlet to increase the inlet water temperature thereby reducing the likelihood of condensation forming on the heat exchanger The pump also serves to circulate water through the heater from the main system piping To complete the installation of the pool heater the pool thermostat needs to be installed in the main return water line This will insure 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 thermostat adjacent to the main line and run wires back to the heater See Figure 9225 Adjustment of the bypass valve is critical to proper operation of the heater The bypass valve should be adjusted to achieve a minimum inlet water temperature of 105 F and an outlet water tempera
25. CATALOG NO 1000 53F Effective 03 01 05 Replaces 10 01 03 OPERATING AND INSTALLATION INSTRUCTIONS Models 122 322 Type H WH amp P FOR YOUR SAFETY Do 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 WARNING Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Refer to this manual Installation and service must be performed by a qualified installer service agency or the gas supplier FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS to light any appliance Donottouch 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 This manual should be maintained in legible condition and kept adjacent to the heater or ina safe place for future reference P N 241112 TABLE OF CONTENTS PAGE NO 11 13 14 16 18 19 21 24 28 31 33 35 37 38 41 42 43 44 46 47 48 49 50 55 SECTION A BEFORE INSTALLING THE HEATER SECTION B HEATER INSTALLATION SECTION COMBUSTION AND VENTILATION AIR SECTION D WATER PIPING GENERAL SECTIONE HYDRONIC HEATING PIPING SECTION F DOMESTIC HOT WATER PIPING SE
26. CTION POOLHEATING SECTIONH GAS SUPPLY CONNECTIONS SECTION I ELECTRICAL POWER CONNECTIONS SECTION J VENTING CONNECTIONS J 1 Natural Draft Vertical Venting J 2 Horizontal Thru Wall Venting J 3 Horizontal Thru Wall Direct Venting J 4 Vertical Direct Venting Combustion Air J 5 Outdoor Installation SECTION CONTROLS WIRING DIAGRAM SECTIONL GENERAL SAFETY PRECAUTIONS SECTION M PRE START UP SECTIONN A HIDELTAINITIAL START UP SECTIONO POST START UP CHECK SECTION P OPERATION SECTION MAINTENANCE APPENDIXA COMBUSTION AIR CONTAMINATION ILLUSTRATED PARTS LIST WARRANTY DWOJE sure the gas on which the heater will operate is the same type as that specified on the heater model and rating plate ZINC 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 appliance 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 minimize the possibility of improper operation serious personal injury fire or damage to the heater never violate the following safety rules 1 Always keep the area around the heater free of combustible materials gasoline and other flammable liquids and
27. DRONIC HEATING PIPING PUMPSELECTION In order to ensure proper performance of your boiler system you must install a properly sized pump Raypak recommends using a 20 F Delta T as design Delta T Delta T is the temperature difference between the inlet and outlet water when the heater is firing at full rate Ifa Delta T larger than 20 F is necessary see Table D 1 for minimum flow rate requirements PRESSURE DROP IN FEET OF HEAD FEEDWATER REGULATOR Raypak recommends that a feedwater regulator be installed and set at 12 PSIG minimum pressure at the highest point of 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 HEATING BOILERS All high points should be vented Purge valves and a bypass valve should be installed A boiler installed above radiation level must be provided with a low water cut off device The boiler when used in connection with a refrigeration system must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler The boiler piping system of a hot water heating boiler 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 boiler water during the cooling cycle It is highly recommend
28. Do not locate adjacent to any window door walkway or gravity air intake The vent must be located a minimum of four 4 feet horizontally or four 4 feet below or one 1 foot above such areas Install above grade level and above normal snow levels Vent terminal must be at least 3 feet above any forced air inlet located within 10 feet Adjacent brick or masonry surfaces must be protected with a rust resistant sheet metal plate Multiple Outdoor Vent installations require a four 4 feet clearance between vent caps NOTICE Condensate can freeze on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition The restricted vent cap must be furnished by the heater manufacturer in accordance with its listing An outdoor air filter supplied by the manufacturer is mounted on the heater 37 SECTION K CONTROLS WARNING WARNING CAUTION CAUTION 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 Turn off the power to the heater before installation adjustment or service of the heater controls Failure to do so may result in heater malfunction property damage personal injury or death This appliance has provisions to be connected to more than one 1 supply
29. LLATION CAUTION All combustion air has to be drawn from the air outside the building the mechanical equipment room directly communicates 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 outdoors The total cross sectional area of such an opening s shall be at least 10 of the area required in 2 and 3 but in no case shall the cross sectional area be less than 10 sq in 6500 Sq mm 2 For heaters using a barometric damper in the vent system and when air supply is provided by natural air flow from the outdoors for natural draft partial fan assisted fan assisted or power draft assisted burners there shall be a permanent air supply opening s having a cross section area of not less than 1 sq in per 7000 BTUH 310 sq mm per kW up to and including 1 million BTUH plus 1 sq in per 14000 BTUH 155 sq mm per kW in excess of 1 million BTUH This opening s shall be either located at or ducted to a point neither more than 18 in 450 mm nor less than 6 in 150 mm above the floor level The duct can also Goose Neck through the roof The duct is preferred straight down 18 from floor but do not place near piping This air supply opening requirement shall be in addition to the air opening for ventilation air required in 1 3 For heaters not using a barometric damper in the ventsystem and when air supply is pro
30. NSOR SYSTEM BS RETURN 15 KEY lol SS ISX Tels PRESSURE RELIEF VALVE PUMP UNION DRAIN VALVE CHECK VALVE BALL VALVE PRESSURE REDUCING VALVE THERMOSTAT AIR VENT THERMOMETER 2X BOILER PUMP Fig M8336 rev 0 Fig 9396 CONTROLLER mu ES KEY 2 2 6 5 4 4 PRESSURE RELIEF VALVE ps PUMP A UNION LAM GATE VALVE M CHECK VALVE Lo BALL VALVE 1 THERMOMETER SECTION F DOMESTIC HOT WATER PIPING When designing the water piping system for domestic water applications water hardness should be considered Table F 1 indicates the suggested flow rates for soft medium and hard water Hardness is specified as grains per gallon TABLE F 1 DOMESTIC WATER HEATER FLOW RATE REQUIREMENTS _ MEDIUM HARD AT GPM AP MPs SHL AT GPM AP MPS SHL AT GPM AP MPS SHL 122 10 20 25 1141 49 8 26 40 114 78 7 30 53 1 1 4 103 162 14 20 25 114 49 11 26 41 114 79 9 30 54 1 1 4 104 9 44 118 112 16 1 32 27 20 27 112 36 20 27 48 1222 66 12 44 122 112 165 Must use optional Cupronickel tubes 162 200 17 20 26 114 50 13 26 42 114 80 22 AT Temperature Rise Degree F A P Pressure Drop Ft thru heat exchanger GPM Gallons Minute Flow Rate SHL
31. OR STAGE CONNECTIONS OF HEATER 2 TO STAGE 2 CONNECTION ON TANKSTAT AS SHOWN IN DIAGRAM Heater must be electrically grounded in accordance with NEC and C22 1 in Canada NOTES 1 Field installed ground to inside of junction box 2 Ifanyofthe original wire as supplied with the heater must be replaced it must be replaced with 105 C wire or its equivalent 23 SECTION J VENTING CONNECTIONS GENERAL CAUTION Proper installation of flue exhaust venting is critical for the safe and efficient operation of the heater Definition of 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 I A heater which operates with a non positive vent static pressure and with a vent gas tempera ture that avoids excessive condensate production in the vent Category II A heater which operates with a non positive vent static pressure and with a vent gas tempera ture that may cause excessive condensate production in the vent Category III 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 J 1 for appliance category requirements for the Hi Delta Note For additional informatio
32. UNIT DOES NOT HAVE A FACTORY WIRED STAGE CONTROLLER THE ON OFF UNIT IS FACTORY WIRED IN ON OFF SAGE CONFIGURATION WITH OTHER STAGE TERMINALS JUMPERED ES FACTORY JUMPERED STAGE CONTROL STAGE STAGE 1 2 5 TO FIELD CONNECT STAGE CONTROLLER 2 STG REMOVE FACTORY INSTALLED JUMPER E UN AND WIRE STAGE CONTROL AS SHOWN SIAGE STAGE CONTROL CONTROL 1 2 Fig 9446 22 ELECTRICAL CONNECTIONS DOMESTIC HOT WATER CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing DANGER SHOCK HAZARD Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components Installer action is required to electrically enable your Hi Delta heater to operate after making the power conections You must make a connection on Terminal Block 3 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 configured to operate in ON OFF firing mode This means that you will connect a single pole control to stage one of stage selector Terminals 1 amp 2 Then jumper t
33. Vent Stack The weight of the vent stack or chimney must not rest on the heater vent connection Support must be provided in compliance with applicable codes The vent should also be supported to maintain proper clearances from combustible materials Use insulated vent pipe spacers where the vent passes through combustible roofs and walls Vent Terminal Location NOTICE During winter months check the vent cap and make sure no blockage occurs from build up of snow Condensate can freeze on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition General Give special attention to the location of the vent termination to avoid possibility of property damage or personal injury a Gases may forma white vapor plume in winter The plume could obstruct a window view if the termination is installed in close proximity to windows b Prevailing winds could cause freezing of condensate and water ice build up on building plants or roof c The bottom of the vent terminal and the air intake shall be located at least 12 in above grade d Un insulated single wall metal vent pipe shall not be used outdoors on cold climates for venting gas utilization equip ment e Through the wall vents for Category II and IV appliances and non categorized condensing appliances shall not termi nate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of reg
34. Z Flex 800 654 5600 Pipe joints must be positively sealed Follow carefully the vent manufacturers installation instructions 34 SECTION J 4 DIRECT VENT Vertical Venting Category D 36 4 VENT CAP MIN 12 MIN IE VENT PIPE INTAKE P di VENT AIR FILTER COMBUSTION BOILER UNIT 2 ut 2 2 Fig 9392 VERTICAL VENTING TABLE MINIMUM CERTIFIED MINIMUM MAXIMUM COMBUSTION AIR INLET MAXIMUM AIR APPLIANCE RECOMMENDED VERTICAL VENTING AIR INTAKE INTAKE LENGTH VENTING CATEGORY MATERIAL HEIGHT FEET PIPE MATERIAL INCHES FEET 40 Galvanized Steel Subtract 10 ft per PVC elbow Type B ABS Equivalent CPVC Maximum two elbows 35 Vertical Direct Vent System Installation These installations utilize the heater mounted blower to draw combustion air from outdoors and uses the natural buoyancy of the heated flue products to create a thermal driving head that expels the exhaust gases from the flue The negative draft must be within the range of 0 01 to 0 08 W C as measured 12 in from the appliance outlet to insure proper operation The vent material must be in accordance with the above instructions for vent materials Vent material must be listed by a nationally recognized test agency The maximum and minimum venting length for Category I appliance shall be determined per the
35. ate vent at least six 6 feet away from adjacent walls f DO NOT terminate vent closer than five 5 feet below roof overhang g The vent terminal ofa direct vent appliance with an input over 50 000 Btu per hour shall require a 12 inch vent terminal clearance h Terminate vent at least one 1 foot above grade including normal snow line i Multiple direct vent installations require a four 4 foot clearance between vent caps 26 Canada Installations Refer to latest edition of CAN CGA B149 1 and 2 A vent shall not terminate a Directly above a paved sidewalk or driveway which is located between two single family dwellings and serves both dwellings b Less than 7 ft 2 13m above a paved sidewalk or paved driveway located on public property c Within 6 ft 1 8m ofa mechanical air supply inlet to any building d Above a meter regulator assembly within 3 ft 900mm horizontally of the vertical centre line of the regulator e Within 6 ft 1 8m of any gas service regulator vent outlet f Less than 1 ft 300mm above grade level g Within the 3 ft 1m ofa window or door which can be opened in any building any non mechanical air supply inlet to any building or the combustion air inlet of any other appliance h Underneath a verandah porch or deck unless i the verandah porch or deck is fully open on a minimum of two sides beneath the floor and 1 the distance between the top of the vent termination and the underside of the verandah porch
36. aypak com 55 Registered Quality System www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 800 872 9725 Raypak Canada LTD 2805 Slough Street Mississauga Ontario Canada LAT 1G2 905 677 7999 Fax 905 677 8036 Litho in U S A
37. but not related to personal injury hazards SECTION A BEFORE INSTALLING THE HEATER Raypak strongly recommends that this manual be reviewed thoroughly before installing your Raypak heater Please review the General Safety Precautions on Section L before installing the heater Factory warranty does not apply to heaters that have been improperly installed or operated 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 factory 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 product it is suggested that you visually 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 some items will be shipped loose Be sure that you receive the correct number of packages as indicated on the Bill ofLading Claims for shortages and damages must be filed with the carrier by 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 a
38. ccepted All returned goods are subject to a restocking charge When ordering parts you must specify the Model and Serial Number ofthe heater When ordering under warranty conditions you must also specify the date of installation Purchased parts are subjectto replacement only under the manufacturer s warranty Debits for defective replacement part will not be accepted and will be replaced in kind only per Raypak s standard warranties MODEL IDENTIFICATION The model identification number and heater serial number are found on the heater data plate located on the left inside Jacket of the heater The model number will have the form H3 0162 or similar depending on the heater size and configuration The first character of the model number identifies application H Hydronic Heating System WH Hot Water Supply System P Pool Application The second character identifies the firing mode 3 two stage firing 4 On Off firing The next four places identify the size of the heater RATINGS AND CERTIFICATIONS STANDARDS Gas Fired Low Pressure Steam and Hot Water Heaters ANSI Z21 13 CSA 4 9 latest edition Industrial and Commercial Gas Fired Package Heaters CAN 31 latest edition Gas Fired Pool Heaters ANSIZ21 56 CSA 4 7 latest edition Gas Water Heaters ANSI Z21 10 3 CSA 4 3 latest edition All Raypak heaters are National Board Approved design certified and tested by the CSA International for U S A and Canada Each
39. densation during start up The condensate from flue gas is slightly acidic In most cases the pH level is not harmful to vents or drains When combustion air is contaminated by vapors from products in areas listed below the acidic levels in the condensate increase Higher acidic levels attack many materials including stainless steel commonly used in high efficiency systems The heater can use special corrosion resistant nonmetallic intake vent material You may however choose to use outside combustion air for one or more of these reasons e installation is in an area containing contaminants listed below which will induce acidic condensation you want to reduce infiltration into your building through openings around windows and doors you are using AL29 4C stainless steel vent pipe which is more corrosion resistant than standard metallic vent pipe In extremely contaminated area this may also experience deterioration Products causing contaminated combustion air spray cans containing chloro fluorocarbons permanent wave solutions e chlorinated waxes cleaners chlorine based swimming pool chemicals calcium chloride used for thawing sodium chloride used for water softening refrigerant leaks paint or varnish removers hydrochloric acid muriatic acid cements and glues antistatic fabric softeners used in clothes dryers chloride type bleaches detergents and cleaning solvents found in household laundry rooms a
40. dhesives used to fasten building products andother similar products Areas causing contaminated combustion air dry cleaning laundry areas and establishments metal fabrication plants beauty shops refrigeration repair shops photo processing plants auto body shops plastic manufacturing plants e furniture refinishing areas and establishments new building construction remodeling areas Check for areas and products as listed above before installing heater If found remove products permanently OR provide outdoor combustion air 49 f i m 9 H E a 22 1 12 8 P 4 2 4 t A y 1 J DETAIL Fig 241093 50 HEAT EXCHANGER DETAIL CALL DESCRIPTION 322 BURNER ASSEMBLY Burner Assy w Burners Includes Front Comb Panel 008525F 008526F 008527F 008528F 008529F 008522F 008522F 008522F 008522F 008522F 007443F 007443F 007443F 007443F 007443F Manifold On Off 008459F 008460F 008461F 008462F 008463F Manifold 2 Stage 008464F 008465F 008466F 008467F 008468F Manifold Gasket 008469F 008469F 008469F 008469F 008469F Burner Orifice Nat 51 35154113 35154114 351541 15 351541 6 35154118 Burner Orifice Pro 63 35144313 35144314 35144315 35144316 35144318 CONTROLS Manual Hi Limit 240 Deg Max H 007144F 007144F 007144F 007144F 007144F Manual Hi Limit 200 Deg WH 008081F 008081F 008081F 008081F 008081F Adj Auto Hi Limit 240 Deg Max H 007141F
41. e as direct as possible and shall be the same diameter 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 clearances and to prevent physical damage or separation of joints e Natural Draft Vertical Vent Termination The vent terminal should be vertical and should terminate outside the building at least two 2 feet above the highest point of the roof that is within 10 feet The vent cap should have a minimum clearance of four 4 feet horizontally from and in no case above or below unless a four 4 foot 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 consistent with the NFGC or in Canada the B149 Installation Code for Gas Burning Appliances and Equipment Gas vents supported only by flashing and extended above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads CAUTION Listed vent cap terminal must be used and sized adequately to evacuate the flue products from the heaters Natural Draft Vertical Venting With Common Venting System Category I Appliance Only Manifolds that
42. ect vent cap MUST be mounted on the exterior 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 one 1 foot above ground level and above normal snow levels Multiple direct vent caps MUST NOT be installed with one 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 combustion air intake installed above This type of installation can cause non warrantable problems with components and poor operation of the unit due to the recirculation of flue products Multiple direct vent caps should be installed in the same horizontal plane with a three 3 foot 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 No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants TheStainless Steel flue exhaust direct vent cap must be furnished by the heater manufacturer in accordance with its listing Use only the special gas vent pipes listed for use with category III gas burning heaters such as the stainless steel vent by Heat Fab Inc 800 772 0739 Protech Systems Inc 800 766 3473 or
43. ed from system Air purged from gas piping Piping checked for leaks Followed start up procedure for proper start up Is burner flame visible 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 controls are tested When safety devices are restored burners should reignite after pre purge time delay 8 limit control While burner is operating move indicator on high limit control below actual heater water temperature Burner should go off while blower and circulator continue to operate Raise setting on limit control above heater water temperature and burner should reignite after pre purge time delay 9 Test ignition system safety device on manual gas valve Turn power on Set thermostat to call for heat When the unit 1s in operation Disconnect combustion air blower pressure switch burner should go off immediately Wait 5 minutes Reconnect combustion air pressure switch burner should reignite after pre purge time delay 10 To restart system follow lighting instructions in Section P 11 High limit control set to design temperature requirements of system For multiple zones flow adjusted as required in each zone 12 Heater cycled with thermostat Raise to highest setting and verify heater goes through normal start up cycle Reduce to lowest setting and verify heater goes of
44. ed that the piping be insulated AIR SEPARATION EXPANSION TANK All boilers should be equipped with a properly sized expansion tank and air separator fitting as shown in the following diagrams THREE WAY VALVES Valves designed to blend water temperatures or reduce water circulation through the boiler should not be used Raypak boilers are high recovery low mass boilers not subject to thermal shock Raypak offers a full line of electric sequencers that produce direct reset of boiler water temperature Refer to the Controls Section in our Complete Catalog Table D 1 BOILER RATE OF FLOW AND PRESSURE DROP 10 F AT 20 F AT 30 F AT MIN FLOW MAX FLOW AP ft 30 54 9 34 N A 22 Flow switch when used will not activate at less than 12 gpm NOTE Basis for minimum flow 10 gpm or 40 Delta T maximum flow 44 gpm except for 1 25 header 14 SINGLE BOILER LOW TEMPERATUREAPPLICATION HEATPUMP PRIMARY SECONDARY PIPING DUAL BOILER PRIMARY SECONDARY PIPING MINIMUM PIPE SIZES MAIN 1 1 4 1 1 2 1 1 2 2 122 202 242 322 EXPANSION TANK SYSTEM SUPPLY z Q MAIN SYSTEM PUMP 7 INLET WATER PRESSURE REGULATOR NOTES TEMPERATURE GAUGES 1 PLUMB SWING CHECK VALVE IN GRAVITY CLOSED POSITION SS TYP 2 PIPE ALL RELIEF VALVES TO DRAIN OR AS LOCAL CODES REQUIRE 6X ISOLATION VALVE p MAIN Qu TEMPERATURE 12 MAX SE
45. eplace access panel TO TURN OFF GAS TO APPLIANCE Set the thermostat to lowest setting Turn off all electric power to the appliance if service is to be performed Remove upper front panel Turn off main manual gas valve Replace access panel If heater fails to start check for Loose connections blown fuse or service switch off Hightemperature limit switch set below heater water temperature Thermostat set below room temperature Gasnotturned on at meter or heater Incoming gas pressure less than 6 W C for natural gas 11 W C for LP gas 47 SECTION Q MAINTENANCE SUGGESTED MINIMUM MAINTENANCESCHEDULE Regular service by a qualified service agency and maintenance must be performed to ensure maximum heater operating efficiency Maintenance as outlined below may be performed by the owner Yearly Beginning of each heating season Annual service call by qualified service agency Visually check top of vent for soot Call service person to clean Some sediment at bottom of vent is normal Visually inspect venting system for proper function deterioration or leakage Check that heater area is free from combustible materials gasoline and other flammable vapors and liquids Check for and remove any obstruction to the flow of combustion or ventilation air to heater Follow pre start up check in Section N Visually inspect burner flame Should see light blue flame Visually inspect hot
46. f 13 Observed several operating cycles for proper operation 14 Set room thermostat or tankstat to desired temperature 15 Reviewed all instructions shipped with this heater with owner or maintenance person returned to envelope and given to owner or placed in pocket inside front panel on heater YP 46 SECTION P OPERATION OPERATINGINSTRUCTIONS Lighting Instructions 1 STOP Read the safety information first 2 Set the thermostat to the lowest setting 3 electric power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the burner Do Not try to light the burner by hand 5 Remove upper front panel 6 Turnonmain manual gas valve 7 Wait five 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 information on the front cover If you do not smell gas go to next step 8 Turn on all electric power to the appliance 9 Setthermostat to desired setting The appliance 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 3 times If ignition is not sensed lockout will commence 10 Ifthe appliance will not operate follow the instruction To Turn Off Gas To Appliance and call your service technician or gas supplier 11 R
47. he remaining firing stages For example if your heater is a 162 you will jumper stage two Then your heater will either be on at full fire or it will be off 2 Formulti stage controller connections connect each stage of the control to the corresponding stage selector terminal block in the heater Stage 1 ofthe heater to stage 1 of the control Stage 2 of the heater to stage 2 of the control and so on Set the operating control at the setpoint in which you want the heater to maintain Ensure that the sensing bulb ofthe control is at the point in the system that will best maintain the temperature you want For example when you are heating a tank of water you want the operating control sensor bulb in the tank Consult the wiring diagram shipped with the heater in the instruction packet The TH connections are for the remote tank control through the heaters 24 volt transformer DO NOT attach line voltage to the TH connection Before starting heater check to ensure proper voltage to heater and pump SINGLE STAGE 2 STAGE TANKSTAT TANKSTAT WwW THY LEADS B BOILER 1 4 pen gt a TH LEADS TH LEADS BOILER 1 R R BOILER 2 ee D DM M gt P ig 9138 1 Fig 9138 2 ATTACH STAGE 1 CONNECTIONS ON HEATER TO ATTACH STAGE 1 CONNECTIONS THE SINGLE STAGE TANKSTAT AS SHOWN IN THE ONHEATER TO STAGE 1 CONNECTION DIAGRAM ABOVE ON TANKSTAT ATTACH STAGE 2 CONNECTIONS
48. he voltage is indicated on the tie in leads Consult the wiring diagram shipped with the heater in the instruction packet The remote tank control stat thermostat or electronic heater control as applicable may be connected to stage selector terminal See wiring diagram 24 Volts are supplied to this connection through the heater transformer DO NOT attach line voltage to the TH leads Before starting the heater check to insure proper voltage to the heater and pump Install a separate disconnect means for each load Use appropriate sized wire as defined by NEC CSA and or local code All primary wiring should be 125 of minimum rating It is strongly recommended that all individually powered control modules and the heater should be supplied from the same power source SURGE PROTECTION Microprocessor based and solid state controls are vulnerable to damage from voltage and amperage fluctuations in the power supply All sensitive control components should be protected by a suitable commercial grade surge protection device Ifany of the original wire as supplied with the heater must be replaced it must be replaced with 105 C wire or its equivalent CHECK THE POWER SOURCE Using a volt ohm meter VOM check the following voltages at the circuit breaker panel prior to connecting any equipment Make sure proper polarity is followed and house ground is proven FIGUREI 1 CHECK POWER SOURCE VOLT OHM METER CIRCUIT BREAKER WHITE
49. heck all thermostats and high limit settings During the following safety checks leave manometers hooked up check and record If other gas fired equipment are in the room and on same gas main check all pressures on the Hi Delta with all other equipment running Remember incoming gas pressure could be lower than specified on page 19 provided 3 2 5 is met Check thermostats for ON OFF operation Check High limits for ON OFF operation While in operation check flow switch operation Check the low gas pressure switches For proper adjustment if available use the attached manometers to set pressure The scales on the switch are approximate only Low gas pressure switch must be set at 5 W C for natural gas and 10 W C for LP gas High gas pressure switch optional at 1 W C above manifold pressure Insert ignition control lockout tests as safety check Follow Up Safety checks must be recorded as performed Turn unit on After main burner ignition Check Manometer for proper reading Cycle unit several times and recheck readings Reanalyze with unit running record or print results Remove all Manometers and replace hose remove jumper replace all gas pressure caps Check for gas leaks one more time 45 SECTION O POST START UP CHECK Check off steps as completed Heater and heat distribution units or storage tank filled with water Automatic air vent if used open two full turns during venting procedure Air purg
50. intain your water pH between 7 4 and 7 8 and total alkalinity between 100 and 150 p p m If the mineral content and dissolved solids in the water become too high scale forms inside the heat exchanger tubes reducing heater efficiency and also damaging the heater If the pH drops below 7 2 the heater will be severely damaged NOTE Heat exchanger damage resulting from chemical imbalance and or scaling is not covered under the warranty 18 SECTION H GAS SUPPLY CONNECTIONS DANGER Make sure the gas on which the heater will operate is the same type as specified on the heater model and rating plate Gas piping must have a sediment trap ahead of the heater gas controls and a manual shut off valve located outside the heater jacket A pounds to inches regulator must be installed to reduce to gas supply pressure to under 14 W C The regulator should be placed a minimum distance of 10 times the pipe diameter upstream of the heater gas controls All gas piping must be tested after installation in accordance with local codes The heater and its gas connection must be leak tested before placing it in operation MANUAL SHUT OFF GAS VALVE FLOW i SUPPLIED GAS SUPPLIED BY OTHERS U FLOW BY OTHERS SHUT OFF E SEDIMENT TRAP VALVE EXTENTS OF 4 EXTENTS OF UNIT ENCLOSURE SEDIMENT TRAP EN TO BURNERS UNION TO BURNERS Fig 9401 1 GAS SUPPLY CONNECTION The heater and its manual shutoff valve m
51. ir plenum MANIFOLD DATA MODEL NUMBER SUPPLY GAS PRESSURE TAP MANIFOLD ADJUSTMENT zz SCREW CAP MANIFOLD GAS PRESSURE TAP Ie BLEEDLE DECREASE VALVE Gas Valve Detail Air Shutter Adjustment SECTION B HEATER INSTALLATION INSTALLATIONCODES Installations must follow these codes Local state provincial and national codes laws regulations and ordinances National Fuel Gas Code ANSI Z223 1 latest edition NFGC National Electrical Code ANSI NFPA 70 latest edition NEC Standard for Controls and Safety Devices for Automatically Fired Heaters ANSI ASME CSD 1 when required CSD 1 For Canada only CAN CGA B149 1 and 2 Installation Code B149 1 and 2 and C S A C22 1 C E C Part 1 C22 1 EQUIPMENT BASE The heater should be mounted on a level structurally sound surface The heater is approved for installation on a combus tible 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 The heater should be located in an area where water leakage will not result in damage to the area adjacent to the appliance or to the structure When such locations cannot be avoided it is recommended that a suitable catch pan adequately drained be installed under the appliance The pan must not restrict air flow In addition the heater shall be installed such that the gas ignitio
52. llow installation in one of the three following combinations 40 of straight flue pipe 30 of straight flue pipe and one elbow 20 of straight flue pipe and two elbows The total length air supply pipe cannot exceed forty 40 feet in length for the combustion air inlet Each elbow used is equal to ten 10 feet of straight pipe This will allow installation in one of the three following combinations 40 of straight combustion air pipe 30 of straight combustion air pipe and one elbow 20 of straight combustion air pipe and two elbows The flue exhaust 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 accumulation of condensate in the vent pipes It is recommended that a The vent be installed with a slight downward slope of not more than 1 4 per foot of horizontal run to the vent terminal b The vent be insulated through the length of the horizontal run For appliances installed in extreme cold climate it is recommended that a The vent be installed with a slight upward slope of not more than 1 4 per foot of horizontal run to the vent terminal In this case an approved condensate trap must be installed per applicable codes b The vent be insulated through the length of the horizontal run Horizontal Thru wall Direct Vent Termination The flue exhaust dir
53. n on appliance categorization see appropriate ANSI Z21 Standard and the latest NFGC or in Canada the B149 Installation Code or applicable provisions of local building codes Determination of Appliance Category for Venting Purposes and Venting Arrangements erm Contact the manufacturer of the vent material if there is any question about the appliance categoriza tion and suitability of a vent material for application on a Category III or IV vent system Using improper venting materials can result in personal injury death or property damage 24 Category Determination for Venting Purpose and Venting Arrangement PHITWSV L c pue 6p g epeueO 10 ODAN OY Jo 18912 IY ut pougop Sy OAdO seo jeeis ssejureis Sav peziueA ec Bunu A Aue Jo g d uB L seo 1995 5 Ulejs g I Aue I3 INI STVIYALVIN 03131 3395 Buus JejuoziuoH yesq BJnjeN NOILVYENSISANOD SNILN3A LSNVHX4 SIN3IN3SNVHHV V L13G IH p is jno UJOJ 199Jiq uoN episu 5 NOILSNEINOD 25 Support of
54. n system components are protected from water dripping spraying rain etc during appliance operation or service circulator replacement control replacement etc UZ Ae This Product Must Be Installed By A Licensed Plumber Or Gas Fitter when Installed Within The Commonweatlh Of Massachusetts CLEARANCES TABLE1 INDOOR INSTALLATION MINIMUM CLEARANCES FROM COMBUSTIBLE SURFACES Models Heater Side 122 322 Floor See Note 1 Rear 1 Water Side 12 Other Side 1 Top 1 Vent 2 Note 1 Do not install on carpeting 1 Fig 9394 TOP VIEW FRONT VIEW When installed according to the listed minimum clearances from combustible construction materials the Raypak 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 front and at least 18 on the water connection side This will enable the heater to be serviced in its installed location that is without movement or removal of the heater Clearances less than minimum 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 Raypak Hi Delta Heaters are design certified for outdoor installation Heaters must not be installed under an overhang that is less than
55. nless Steel direct vent cap must be furnished by the heater manufacturer in accordance with its listing Use only the special gas vent pipes listed for use with category HI gas burning heaters such as the stainless steel vent by Heat Fab Inc 800 772 0739 Protech Systems Inc 800 766 3473 or Z Flex 800 654 5600 Pipe joints must be positively sealed Follow carefully the vent manufacturers installation instructions 32 SECTION J 3 DIRECT VENT Horizontal Thru wall Venting Category IID 12 VENT PIPE VENT CAP INTAKE VENT 36 MIN INTAKE P VENT 12 MIN I bE COMBUSTION AIR FILTER BOILER UNIT 777 Z e Fig 9391 HORIZONTAL THRU WALL VENTING TABLE CERTIFIED MAXIMUM COMBUSTION AIR AIR INLET MAXIMUM AIR VENTING VENTING LENGTH INTAKE PIPE SIZE INTAKE LENGTH MATERIAL FEET MATERIAL INCHES FEET APPLIANCE CATEGORY 40 40 Galvanized Steel Stainless Steel ft per PVC 5 ft per Gas Tight Maximum two ABS Maximum two CPVC elbows elbows 33 Horizontal Thru wall Direct Vent System Category IIT Installation These installations utilize the heater mounted blower to draw combustion air from outdoors and vent combustion products to the outdoors The total length of the thru wall exhaust vent cannot exceed forty 40 feet in length for the flue outlet Each elbow used is equal to ten 10 feet of straight pipe This will a
56. om gas line up to heater gt gt 43 SECTION N INITIAL START UP 1 0 TOOLS NEEDED One 12 0 12 24 scale manometer Two 6 0 6 12 scale manometers 7 16 open end wrench 1 2 open end wrench Screwdriver Volt meter 3 16 Allen wrench 2 0 PREPARATION FOR START UP Y eee DO NOT TURN ON GAS AT THIS TIME 2 1 Check Power Supply With volt meter at incoming power check voltage between Hot Common 120 VAC Hot Ground 120 VAC Common Ground lt 1 VAC If Common Ground is gt VAC STOP Contact electrician to correct ground failure Warning Failure to do this may burn out 120V 24V transformer or may cause other safety control damage or failure 2 2 Attach Manometers to Measure Pressures e Attach 24 scale manometer to the first main gas shut off valve pressure tapping e Attach one 12 scale manometer to the manifold gas pressure tapping See gas valve detail on page 7 Attach one 12 scale manometer to Pull rubber tube from air pressure switch off the aluminum tubing and connect the manometer using a tee Turn Off Main Gas Valve 2 3 Check the Gas Supply Pressure Slowly turn on main gas shut off valve 2 Readthe gas supply pressure from the manometer minimum supply pressure is 5 W C recommended supply is 7 W C for natural gas minimum 12 W C for LP gas 3 Ifpressure is gt 14 W C turn off the valve 4 Check if the service regulator
57. onnections 008413F 008414F 008415F 008416F 008417F Heat Exch Cast Iron Cupro Nickel Side Connections 008418F 008419F 008420F 008421F 008422F Heat Exch Brass Cupro Nickel Side Connections 008423F 008424F 008425F 008426F 008427F Heat Exch Cast Iron Top Connections ASME 008658F 008659F 008660F N A N A Heat Exch Cast Iron Top Connections NON ASME N A N A Inlet Outlet Header Cast Iron Side Connections 008428F 008428F 008428F 008429F 008429F Inlet Outlet Header Brass Side Connections 008430F 008430F 008430F 008431F 008431F Inlet Outlet Header Cast Iron Top ASME 004236F 004236F 004236F N A N A Inlet Outlet Header Cast Iron Top NON ASME 008670F 008670F 008670F N A N A Return Header Cast Iron 008432F 008432F 008432F 008432F 008432F Return Header Brass 008433F 008433F 008433F 008433F 008433F Tube Bundle Side Connections 008434F 008435F 008436F 008437F 008438F Tube Bundle Cupro Nickel Side Connections 008439F 008440F 008441F 008442F 008443F Tube Bundle Top Connections 008672F 008673F 008674F N A N A Heat Exchange Tube 008444F 008445F 008446F 008447F 008448F Heat Exchange Tube Cupro Nickel 008449F 008450F 008451F 008452F 008453F Baffle Kit 008454F 008455F 008456F 008457F 008458F 007870F 007870F 007870F 007870F 007870F 800203B 800203B 800203B 800203B 800203B Sensor Well 007211F 007211F 007211F 007211F 007211F Well Retaining Clip 300203 300203 300203 300203 300203 CONTROL BOX Control Assy H 008524F 008524F 008524F 008524F 008524F Control Assy WH 009824F 009824F 0
58. ow 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 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 problem 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 autho
59. paces crawl or attic that freely communicate with the outdoors a Where directly communicating with the outdoors or where communicating to the outdoors through vertical ducts each opening shall have a minimum free area of 1 sq in per 4000 Btu per hr 5 5 cm per kW of total input rating of all equipment in the enclosure b Where communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 sq in per 2000 Btu per hr 11 cm per kW of total input rating of all equipment in the enclosure 2 One permanent opening commencing within 12 in 30 cm of the top of the enclosure shall be permitted where the equipment has clearances ofat least 1 in 2 5 cm from the sides and back and 6 in 16 cm from the front ofthe appliance The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces crawl or attic that freely communicate with the outdoors and shall have a minimum free area of a 1 sq in per 3000 Btu per hr 7 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 Do not use one permanent opening method if the equipment room is under negative pressure condition or the equipment is common vented with other gas fired appliances 11 COMBUSTION AND VENTILATION AIR SUPPLY FOR CANADA INSTA
60. re burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before setting temperature at water heater Feel water before bathing or showering Temperature limiting valves are available see note below 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 The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications Temperature Time to Produce Serious Burn Temperature Time to Produce Serious Burn 120 F More than 5 minutes 140 F Less than 5 seconds 125 F 1 1 2 to 2 minutes 145 F Less than 3 seconds 130 F About 30 seconds 150 F About 1 1 2 seconds 135 F About 10 seconds 155 F About 1 second Table courtesy of The Shriners Burn Institute TIME TEMPERATURE RELATIONSHIPS IN SCALDS The temperature of the water in the hot water heater can be regulated by setting the temperature dial on front of the thermostat To comply with safety regulations the thermostat was set at its lowest setting before the hot water heater was shipped from the factory The illustration below shows the thermostat and how to adjust the water temperature To adju
61. rized to make any other warranties on Raypak s behalf THIS WARRANTY IN LIEU OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABIL ITYAND FITNESS FORAPARTICULAR PURPOSE RAYPAK S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECtTTO 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 FORANY 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 Q N 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 Name of Owner Name of Dealer Address Address Model No Serial No Date of Installation Date of Initial Operation CORPORATE HEADQUARTERS RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 800 872 9725 www r
62. s 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 the 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 recommended that a The vent be installed with a slight downward slope of not more than 1 4 per foot of horizontal run to the vent terminal b The vent be insulated through the length of the horizontal run For appliances installed in extreme cold climate it is recommended that a The vent be installed with a slight upward slope of not more than 1 4 per foot of horizontal run to the vent terminal In this case an approved condensate trap must be installed per applicable codes b The vent be insulated through the length of the horizontal run Horizontal Thru wall Direct Vent Termination The flue exhaust direct vent cap MUST be mounted on the exterior 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 one 1 foot above ground level and above normal snow levels The Raypak supplied flue exhaust direct vent cap must be utilized WARNING No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants The Stai
63. st the water temperature insert a small straight screwdriver into slotted screw in hole in front of thermostat Adjustment and turn wheel to desired setting Screw n CAUTION Hotter water Increases the risk of SCALDING There is a Hot Water SCALD Potential if the thermostat is set too high NOTE When this hot water heater is supplying general purpose hot water requirements for use by individuals a thermo statically 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 42 SECTION M PRE START UP FILLINGSYSTEM HEATING HEATERS Fill system with water Purge all air from the system using purge valve sequence After system is purged of air lower system pressure Open valves for normal system operation fill system through feed pressure Manually open air vent on the compression tank until water appears then close vent DOMESTIC HOTWATER HEATERS Purge all air from system before lighting heater This can be normally be accomplished by opening a downstream valve INSPECT VENTING SYSTEM 1 Check all vent pipe connections and flue pipe material 2 Ensure vent terminations are installed per code and are clear of all debris or blockage FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing proper
64. surface igniter for damage cracking or debris build up Check operation of safety devices Refer to manufacturer s instructions Follow oil lubricating instructions on circulator Over oiling will damage circulator Water lubricated circulators do not need oiling 10 To avoid potential of severe burn DO NOT REST HANDS ON OR GRASP PIPES Use a light touch return piping will heat up quickly 11 Check blower and blower motor Clean and oil as necessary 12 Check for piping leaks around circulators relief valves and other fittings Repair if found DO NOT use petroleum based stop leak Daily 1 Check that heater area 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 function deterioration or leakage 4 Check air vents for leakage Quarterly 1 Check relief valve Refer to manufacturer s instructions on valve 2 Test low water cut off if used Refer to manufacturer s instructions 3 Clean screen and air filter in intake 48 APPENDIX A INSIDECOMBUSTIONAIR CONTAMINATION All heaters experience some con
65. ture between 120 and 140 F When starting with cold pool make initial adjustments Make final adjustments when pool water approaches desired temperature AUTOMATIC CHLORINATORS AND CHEMICAL FEEDERS All chemicals must be introduced and completely diluted into the pool or spa water before being circulated through the heater Do not place chlorine tablets or bromine sticks in the skimmer High chemical concentrations will result when the pump is not running i e overnight Chlorinators must feed downstream of the heater and have an anti siphoning device to prevent chemical backup 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 to the heat exchanger in the heater Such damage is not covered under the warranty WINTERIZING YOU HEATER When heaters installed outdoors in freezing climate areas are to be shut down for the winter please observe the following procedure 1 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 piping from the in out header of the heater Drain the heater and any piping of all water that may experience below freezing temperatures POOL AND SPA WATER CHEMISTRY NOTE Chemical imbalance can cause severe damage to your heater and associated equipment Ma
66. ty damage personal injury or loss of life 1 This appliance does have an intermittent pilot It is equipped with an ignition device which automatically lights the pilot DO NOT try to light the pilot or burner by hand 2 BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor 3 WHATTO 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 neighbor s telephone Follow the gas supplier s instructions e Ifyou cannot reach your gas supplier call the fire department 4 Use only your hand to push in or turn the gas control knob Never use tools If the knob will not turn by hand do not try to repair it call a qualified service technician Forced or attempted repair may result in a fire or explosion 5 Donotuse 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 6 Check around unit for debris and remove combustible products 1 e gasoline etc PRE START UP CHECK Verify heater is filled with water Check system piping for leaks If found repair immediately Vent air from system Air in system can interfere with water circulation Purge air fr
67. ulators relief valves or other equipment Where local experience indicates that condensate is a problem with Category I and III appliances this provision shall also apply f Locate and guard vent termination to prevent accidental contact by people or pets g DO NOT terminate vent in window well stairwell alcove courtyard or other recessed area unless previously approved by local authority h DO NOT terminate above any door window or gravity air intake Condensate can freeze causing ice formations i Locate or guard vent to prevent condensate from damaging exterior finishes Use a 2 x 2 rust resistant sheet metal backing plate against brick or masonry surfaces j DO NOT extend exposed vent pipe outside of building Condensate could freeze and block vent pipe US Installations Refer to latest edition of NFGC Vent termination requirements are as follows a Vent must terminate at least four 4 feet below four 4 feet horizontally or one 1 foot above any door window or gravity air inlet to the building b The vent must not be less than seven 7 feet above grade when located adjacent to public walkways c Terminate vent at least three 3 feet above any forced air inlet located within ten 10 feet d Vent must terminate at least four 4 feet horizontally and in no case above or below unless four 4 feet horizontal distance is maintained from electric meters gas meters regulators and relief equipment e Termin
68. ust be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1 2 PSIG 3 45 KPA The heater must be isolated from the gas supply piping system by closing the manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 PSIG Relieve test pressure in the gas supply line before 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 covered 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 open flame CAUTION Do not use Teflon tape on gas line pipe thread A pipe compound rated for use with gas systems is recommended Apply sparingly only on male pipe ends CAUTION Support gas supply piping with hangers not by the heater or its accessories Ensure the gas piping is protected from physical damage and freezing where required GAS SUPPLY PRESSURE minimum of 7 and a maximum of 10 5 W C upstream gas pressure is required under no load conditions for natural gas A minimum of 12 W C and a maximum of 13 W C is required for propane gas The gas pressure regulator supplied on the heater is for low pressure service If upstream pressure exceeds 14 W C an intermediate gas pressure regulator of
69. vere burns Do not pipe to any area where freezing could occur Refer to local codes HYDROSTATIC TEST Unlike many other types of heaters Raypak heaters do not require hydrostatic testing prior to being placed in operation The heat exchanger has already been factory tested and is rated for 160 PSI maximum operating pressure However Raypak does recommend hydrostatically testing 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 antifreeze Raypak recommends conducting the hydro static 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 1 Connect fill water supply Fill heater with water be sure bleed valve is open When water flows from bleed valve shut off water Close bleed valve Carefully fill the rest of the system being sure to eliminate any entrapped air by using high point vents Close feed valve Test at standard operating pressure for at least 24 hours 2 Make sure constant gauge pressure has been maintained throughout test 3 Check for leaks Repair if found LOW TEMPERATURE SYSTEM Heater requires minimum inlet temperature of 105 F Consult sections E F for piping details TEMPERATURE amp PRESSURE GAUGE The temperature and pressure gauge is factory mounted in the inlet outlet header SECTION E HY
70. vided 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 supply opening s having a total cross sectional area of not less than 1 sq in for each 30 000 BTUH 70 sq 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 1 This opening s can be ducted to a point neither more than 18 in 450 mm nor less than 6 in 150 mm above the floor level The duct can also Goose Neck through the roof The duct is preferred to be straight down 18 from floor but do not place near piping 4 Refer to the latest version ofthe B149 1 and 2 for additional information 12 SECTION D WATER PIPING GENERAL The heater should be located so that any water leaks will not cause damage to the adjacent area or structures CAUTION This heater requires forced water circulation when the burner is operating See Table D 1 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 RELIEF VALVE PIPING Pressure relief valve discharge piping must be piped near the floor close to a floor drain to eliminate the potential of se

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