Hi Delta 992A Installation And Operating Instructions Manual

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INSTALLATION AND OPERATING

Models

992A-2342A Types H, WH & P

WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property dam-

age, personal injury or death.

FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other com-

bustable materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or the

gas supplier.

This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for

future reference.

CATALOG NO. 1000.511A

INSTRUCTIONS

Effective: 09-08-06

Replaces: 03-15-05

P/N 241259 Rev. 1

Table of Contents

Summary of Contents for Hi Delta 992A

Page 1 INSTALLATION AND OPERATING INSTRUCTIONS Models 992A-2342A Types H, WH & P WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property dam- age, personal injury or death. FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other com- bustable materials in the vicinity of this or any other appliance.
Page 3: Table Of Contents
CONTENTS WARNINGS APPENDIX BEFORE INSTALLATION Inside Air Contamination Product Receipt WARRANTIES Model Identification Type H and WH Ratings and Certifications Type P Component Locations General Information GENERAL SAFETY Time/Temperature Relationships in Scalds INSTALLATION Installation Codes Equipment Base Stacking Clearances Combustion and Ventilation Air Conventional Combustion Air Supply 13 Water Piping Hydronic Heating...
Page 4: Warnings
WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe person- DANGER: al injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored.
Page 5: Before Installation
Raypak strongly recommends that this manual be re- application (H = Hydronic Heating, WH = Domestic viewed thoroughly before installing your Hi Delta Hot Water (DHW), P = Pool). The number which fol- heater. Please review the General Safety information lows identifies the firing mode (1 or 4 = on-off, 3 = before installing the heater.
Page 6: Component Locations
Component Locations Fig. 1: Component Locations – Back Fig. 2: Component Locations – Left Side Panels removed for clarity Fig. 3: Component Locations – Front...
Page 7: General Information
General Information Vent Size Quantity of (in.) Model Burners Blowers Flue Intake Valves 992A 2 + 1* 1262A 3 + 1* 1532A 1802A 2002A 2072A 2342A * Hidden solenoid located inside of air plenum. Table A: Basic Data Burners per Valve...
Page 8: General Safety
GENERAL SAFETY To meet commercial hot water use needs, the high limit safety control on this water heater is adjustable up to 210°F. However, water temperatures over 125°F can cause instant severe burns or death from scalds. When supplying general purpose hot water, the rec- ommended initial setting for the temperature control is 125°F.
Page 9: Installation
(See Fig. 4.). Stacking Hi Delta units can be stacked two units high with an optional stacking rack. A seismic-certified stacking kit is available from Raypak for this type of installation.
Page 10 Fig. 6: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations U.S. Installations Canadian Installations Clearance above grade, veranda, porch, 1 ft (30 cm) 1 ft (30 cm) deck, or balcony 4 ft (1.2m) below or to side Clearance to window or door that may be of opening;...
Page 11: Clearances
In addition, the heater shall be installed such that the When installed according to the listed minimum clear- gas ignition system components are protected from ances from combustible construction, these heaters water (dripping, spraying, rain, etc.) during appliance can still be serviced without removing permanent operation or service (circulator replacement, control structural construction around the heater.
Page 12: Combustion And Ventilation Air
Reversing Air Filter Follow these instructions to change the air duct con- nection from the left-hand side (standard) to the right- hand side: 1. Remove the four screws and the dust cover from the right-hand side of the heater. 2. Remove the four screws and the air filter bracket from the left-hand side of the heater.
Page 13: Conventional Combustion Air Supply
TruSeal heater connection points are available as fol- lows: a. Where directly communicating with the out- doors or where communicating to the out- 992A to 1802A Left side – standard doors through vertical ducts, each opening Right side – optional shall have a minimum free area of 1 in.
Page 14: Water Piping
b. Not less than the sum of the areas of all vent of not less than 1 in. for each 30,000 BTUH mm connectors in the confined space. 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 WARNING: Do not use one permanent opening ventilation air referred to in (1).
Page 15 5. Remove all plumbing fittings to the header. This Hydrostatic Test will include both inlet and outlet water pipe unions and the pressure relief valve and drain piping. Unlike many types of heaters, this heater does not re- quire hydrostatic testing prior to being placed in opera- 6.
Page 16: Hydronic Heating
Table H for flow rate requirements. 20°F T 30°F T 40°F T Min. Flow Max Flow Model P (ft) P (ft) P (ft) P (ft) T gpm P (ft) 992A 13.1 1262A 14.8 1532A 15.7 16.5 1802A 10.7 18.3 2002A 13.8 19.0 2072A 14.8...
Page 17 Pressure Drop in Feet of Head heaters which are not subject to thermal shock. Raypak offers a full line of electronic sequencers that Feedwater Regulator produce direct reset of heater water temperature. (Refer to the Controls section of the Raypak Catalog.) Raypak recommends that a feedwater regulator be in- stalled and set at 12 psi minimum pressure at the high- est point of the system.
Page 18 The Hi Delta pool heater is equipped with an external pump and bypass arrangement as standard equip- ment. This arrangement blends outlet water with the...
Page 19 circulate water through the heater from the main sys- perature to 105°F and Valve A is fully open, then tem piping. slowly throttle Valve B closed to increase the inlet water temperature to 105°F. To complete the installation of the pool heater, the pool thermostat needs to be installed in the main return wa- ter line, upstream of the heater.
Page 20: Gas Supply
shut-off. Close isolation valves and remove water pip- Total Dissolved Solids ing from the in/out header on the heater. Drain the heater and any piping of all water that may experience Total dissolved solids (TDS) is the measure of all min- below-freezing temperatures.
Page 21 2” 2-1/2” 3” 4” Model 992A 1262A 1532A 1802A 2002A 2072A 2342A Natural gas – 1,000 BTU per ft , .60 specific gravity at 0.5 in. WC pressure drop Propane gas –...
Page 22: Electrical Power Connections
8. Remove the rubber grommet from the left-hand- Electrical Power Connections side panel and reinstall into the standard main gas opening, located on the right-hand side of the Installations must follow these codes: heater. • National Electrical Code and any other national, 9.
Page 23: Field Wiring Connection
prior to working with any electrical connections or components. BLACK CIRCUIT BREAKER 3. Observe proper wire colors while making electri- WHITE cal connections. Many electronic controls are po- larity sensitive. Components damaged by improp- GREEN er electrical installation are not covered by warran- GROUND 4.
Page 24 DANGER: SHOCK HAZARD Make sure electrical power to the heater is discon- nected to avoid potential serious injury or damage to components. Fig. 21: On-Off Wiring Connections Fig. 23: 3-Stage Wiring Connections Fig. 24: 4-Stage Wiring Connection Fig. 22: 2-Stage Wiring Connections...
Page 25: Venting
Installer action is required to electrically enable your SINGLE STAGE heater to operate after making the power connections. TANKSTAT You must make a closed contact connection on Stage 1 connector of the Central Point Wiring (CPW) board for temperature control connections. This will be done based on the controller option selected with your heater order.
Page 26 Category III – A heater which operates with a positive Vent Terminal Location vent pressure and with a vent gas temperature that avoids excessive condensate production in the vent. NOTE: During winter months check the vent cap and make sure no blockage occurs from build-up of Category IV –...
Page 27: Changing The Flue Outlet
8. Locate and guard vent termination to prevent acci- Canadian Installations dental contact by people or pets. Refer to latest edition of B149.1. 9. DO NOT terminate vent in window well, stairwell, alcove, courtyard or other recessed area. A vent shall not terminate: 10.
Page 28: Venting Installation Tips
Type B vent is: 10 in. location. for Model 992A; 12 in. for Models 1262A and 1532A; 14 in. for Models 2002A and 2072A; and 16 in. for 8. Make sure that the stainless steel cover, now lo- 2342A.
Page 29 Vertical Venting Air Inlet Certified Combustion Air Height* Max. Length** Model Venting Vent Size Intake Pipe Material Material Min. Max. 10” 12” 992A 10” 75’ 100’ 1262A 12” Galvanized Steel, 1532A Category I PVC, (Type B 1802A 5’ 25’ ABS, Equivalent) 14”...
Page 30 speed. Do not operate summer exhaust fan. Close The total length of the horizontal through-the-wall flue fireplace dampers. system should not exceed 70 equivalent ft in length. If horizontal run exceeds 70 equivalent ft, an appropri- 4. Place in operation the appliances being inspected. ately sized extractor must be used.
Page 31 Combustion Air Inlet Certified Maximum Model Max. Length* Venting Vent Size Equivalent Intake Pipe Material Vent Length* 10” 12” Material 992A 10” 70’ 75’ 100’ 1262A 12” Room Air Galvanized 1532A Steel, 1802A Category III 40’ PVC, Ducted ABS, 2002A 14”...
Page 32 For installations in extremely cold climate, it is re- Direct Vent - Vertical quired that: 1. The vent must be installed with a slight upward slope of not more than 1/4 inch per foot of hori- zontal run to the vent terminal. In this case, an ap- proved condensate trap must be installed per ap- plicable codes.
Page 33: Controls
Flues supported only by flashing and extended above NOTE: Condensate can freeze on the vent cap. the roof more than 5 ft should be securely guyed or Frozen condensate on the vent cap can result in a braced to withstand snow and wind loads. blocked flue condition.
Page 34: Heater Sequence Of Operations
Heater Sequence of Operation 14. Once all safeties have been verified to be closed, a 24 VAC signal is output from pin P3-16 of the Models 992A-1262A Universal Diagnostic Board. 15. Relay K-1 (N.C.) will now be energized, and opens 1.
Page 35 External Lights Light Color Indication Power Blue Main power is on Call For Heat Yellow Thermostat is closed One or more safeties is inopera- Safety tive Ignition Ignition module is inoperative Flow Green Flow is present Blower 1 Green Blower 1 is on Blower 2 Green Blower 2 is on...
Page 36 49. The stage 3 LED on the diagnostics display board by a 120 VAC signal from S-1 on the ignition mod- is now illuminated (end of sequence for 992A). ule. (The hot surface igniter must draw greater than 3.1 amps while being energized or ignition 50.
Page 37 9. 24 VAC is sent to the low water cut-off (optional) 21. 24 VAC switched power is applied to the S24V ter- and the red power light is energized. minal on ignition modules 1 and 2. 10. 24 VAC is applied to the blue power light located 22.
Page 38 37. 24 VAC is now sent to the pressure switch (P.S.) 49. Power is applied to the “TH” terminal of ignition terminal on ignition modules 1 and 2. module 2. 38. Once the pressure switch signal is received at 50. Once the “TH” signal is received at ignition module ignition module 1, hot surface igniter 1 is ener- 2, the hot surface igniter 2 is energized by a 120 gized by a 120 VAC signal from S-1 on ignition...
Page 39 6. Terminals L1 and F1 of the ignition module 2 are closes the contacts to allow the unit to fire at stage powered with 120VAC. 7. 120 VAC power is waiting at relay contacts K-4 to 20. After the standby switch is placed into the “ON” energize the heater blowers.
Page 40 35. Power is applied to the optional equipment inter- 47. After the 5-second countdown from TD-2 the inter- lock connection (normally jumpered). nal contacts close allowing 24 VAC to sit at pin 3 of the stage 2 connection on the CPW board. 36.
Page 41 The optional single-try ignition module will lock out Ignition Module after failing to light one time. To reset it, press and release the small, recessed black push button located When additional heat is needed, the combustion air inside of the cut-out on the lower right-hand corner of blower starts to purge air from the combustion cham- the ignition module case.
Page 42 General Safety Section for safety precautions con- cerning domestic hot water applications. Fig. 35: Operating Control Low Water Cut-Off (Optional) Fig. 37: High/Low Gas Pressure Switch The low water cut-off automatically shuts down the burner whenever water level drops below the level of the sensing probe.
Page 43: 87%-Efficiency Boilers - Special Instructions
An See Table P for appliance category requirements for 87%-efficiency boiler operated with an inlet tempera- the 87%-efficiency Hi Delta. ture of less than 120ºF (49ºC) must have a manual bypass or an approved low-temperature operation NOTE: For additional information on appliance cat- system to prevent problems with condensation.
Page 44 11. Locate or guard vent to prevent condensate from WARNING: Contact the vent material manufactur- damaging exterior finishes. Install a rust-resistant er if there are any questions about the appliance cat- sheet metal backing plate against brick or mason- egory or suitability of a vent material for Category II, ry surfaces.
Page 45 pressure reading must be between -0.01 and -0.1 in. WARNING: Vent connectors serving appliances WC as measured 12 in. from the appliance flue outlet. vented by natural draft shall not be connected into Each elbow used is equal to 10 ft of straight pipe. This any portion of mechanical draft systems operating will allow installation in one of the four following com- under a positive pressure.
Page 46 The stainless steel direct vent cap must be furnished The flue exhaust direct vent cap is not considered in by the boiler manufacturer in accordance with its list- the overall length of the venting system. ing (sales order option D-15). Care must be taken during assembly that all joints are Use only double-wall vent pipe and the special gas sealed properly and are airtight.
Page 47 Direct Vent - Vertical Note: When vertical height exceeds 25 ft, consult factory prior to installation. Fig. 43: Direct Vent - Vertical Vertical Venting Air Inlet Certified Combustion Air Height* Max. Length** Model Venting Vent Size Intake Pipe Material Material Min.
Page 48: Wiring Diagrams
Wiring Diagrams...
Page 50: Start-Up
START-UP • If you cannot reach your gas supplier, call the fire department. • Use only your hand to push in or turn the gas con- Pre Start-up trol knob. Never use tools. If the knob will not turn by hand, do not try to repair it, call a qualified serv- Filling System (Heating Boilers) ice technician.
Page 51: Start-Up
Preparation Start-Up Blower Adjustment WARNING: Do not turn on gas at this time. 1. Turn off power. Check Power Supply 2. Unplug cap at pressure switches and connect ma- With multi-meter at incoming power, check voltage nometer(s) to the tee. between: 3.
Page 52 On the manual valve, this is a bleedle valve. Identical readings will be found at the plugged port labeled as The Hi Delta heaters, depending on their size, have Alternate C. one to three burner sections. Each burner section is supplied gas by gas valves incorporated into a single Refer to Fig.
Page 53 1. Manually close the downstream leak test valve. This completes leak testing for a single Hi Delta mani- fold riser. Repeat steps 1-8 for each riser. 2. Open test point A and connect a manometer to it. Verify that there is gas pressure and that it is with- Post Start-Up Check in the proper range (NOTE: must not exceed 14.0...
Page 54: Operation
10. To restart system, follow lighting instructions in the 9. Set thermostat to desired setting. The appliance Operation section. will operate. The igniter will glow after the pre- purge time delay (15 seconds). After igniter reach- 11. Check to see that the high limit control is set es temperature (45 seconds) the main valve will above the design temperature requirements of the open.
Page 55: Troubleshooting
TROUBLESHOOTING Does the power switch provide power to the Check the switch control panel? Step 1 and/or line voltage Replace ignition module Is there a Call For Heat? Unit is in standby mode. Check all safety limit devices and voltage from the transformer to J10 on Reattach.
Page 56: Maintenance
Schedule annual service call by qualified service agency. The following is required procedure in CSD-1 states 1. Visually check top of vent for soot. Call service and good practice for all Hi Delta installations. person to clean. Some sediment at bottom of vent is normal. Daily 2.
Page 57 Weekly 2. Test high limit and operating temperature. (See “Post Start-Up Check,” page 53.) For low-pressure heaters, test low-water cut-off 3. Check flame sensors. device. (With at least one stage of the appliance on, depress the low water cut-off test button, appliance 4.
Page 58 APPENDIX • furniture refinishing areas and establishments • new building construction • remodeling areas Inside Air Contamination • open pit skimmers Check for areas and products listed above before in- All heaters experience some condensation during stalling heater. If found: start-up.
Page 59 LIMITED PARTS WARRANTY HI DELTA – TYPES H AND WH MODELS 992A–2342A 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.
Page 60 LIMITED PARTS WARRANTY HI DELTA – TYPE P MODELS 992A–2342A 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.
Page 64 www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Raypak Canada Limited, 2805 Slough St., Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 Fax (905) 677-8036 Litho in U.S.A.

This manual is also suitable for:

1532a 1802a 2002a 1262a 2072a 2342a