Raypak HI DELTA 302B Installation & Operating Instructions Manual
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Raypak HI DELTA 302B Installation & Operating Instructions Manual

H, wh and p series
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INSTALLATION & OPERATING
Models
302B–902B
Types H, WH & P
WARNING: If these instructions are not followed exactly, a fire or explosion may
result causing property damage, personal injury or death.
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and
liquids or other combustible materials in the vicinity of this or any other appliance.
To do so may result in an explosion or fire.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for
future reference.
CATALOG NO. 1000.501J
INSTRUCTIONS
Effective: 03-29-11
L
W
Replaces: 06-18-10
P/N 240757 Rev. 11

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  • Page 1 INSTALLATION & OPERATING INSTRUCTIONS Models 302B–902B Types H, WH & P WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death. FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance.
  • Page 2 Rev. 11 reflects the following: Changes to: “Installations at Elevation” and low-lead certification on page 5, Table J on page 20, “Electrical Power Connections” on page 22, Table T on page 40, Wiring Diagram on page 45, Igniter check (“As Required” Item #4) on page 53, Warranty on page 56, Fax number in Start-Up Checklist on page 57 Additions: Note on page 15, notes on page 16, Table R on page 39 Deletions: None...

  • Page 3: Table Of Contents

    WARNINGS BEFORE INSTALLATION Product Receipt Model Identification Ratings and Certifications Installations at Elevation Component Locations General Information GENERAL SAFETY Time/Temperature Relationships in Scalds INSTALLATION Installation Codes Equipment Base Stacking Clearances Combustion and Ventilation Air Conventional Combustion Air Supply 13 Water Piping Hydronic Heating Gas Supply Electrical Power Connections...

  • 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

    If, after reviewing this manual, you still have questions which this manual does not answer, please contact the manufacturer or your local Raypak representative. Thank you for purchasing a Raypak product. We hope you will be satisfied with the high quality and durability of our equipment.

  • 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 Quantity of Model Burners Blowers Flue Intake Valves 302B 402B 502B 652B 752B 902B Table A: Basic Data # Burners per Stages Model Valve 302B 402B 502B 652B 752B 902B 1, 2 1, 2, 3 66 Table B: Manifold Data # Burners Valve Model...

  • 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

    Hi Delta units can be stacked two units high with an optional stacking rack. A stacking kit is available from Raypak for this type of installation. CAUTION: The heaters should be located in an area where water leakage will not result in damage to the area adjacent to the appliances or to the structure.

  • Page 10: Clearances

    In addition, the heater shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation or service (circulator replacement, control replacement, etc.). Clearances Indoor Installations Minimum Clearance Heater from Combustible Side Surfaces Floor*...
  • Page 11 Fig. 7: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations Clearance above grade, veranda, porch, deck, or balcony Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal dis- tance of 2 ft (61cm) from the centerline of the terminal...

  • Page 12: Combustion And Ventilation Air

    3. In cold climates, and to mitigate potential freeze- up, Raypak highly recommends the installation of a motorized sealed damper to prevent the circula- tion of cold air through the heater during the non-operating hours.

  • Page 13: Conventional Combustion Air Supply

    three or four sheet metal screws (not supplied) equal- ly distributed around the circumference of the duct. All ducting should be self-supported. The filter housing is not designed to support the air duct. CAUTION: Use TrueSeal combustion air if damaging airborne contaminants are or will be present in the heater area.

  • Page 14: Water Piping

    b. Not less than the sum of the areas of all vent connectors in the confined space. WARNING: Do not use one permanent opening method if the equipment room is under negative pressure conditions or the equipment is common vented with other gas-fired appliances. Canadian Installations CAUTION: All combustion air must be drawn from the air outside of the building;...

  • Page 15: Hydrostatic Test

    CAUTION: Damaging internal condensation may occur if the heater inlet water temperature does not exceed 105ºF (41ºC) within 7 minutes of start-up. NOTE: See Raypak Catalog No. 1000.57 for infor- mation on Cold Water Protection. A heater operated with an inlet temperature of less than 105ºF (41ºC) must have a manual bypass or an...

  • Page 16: Hydronic Heating

    Failure to exceed 105ºF (41ºC) within 7 minutes may result in the premature failure of the hot surface ignit- er, remote flame sensor, burners and heat exchanger. It can cause operational problems, bad combustion, sooting, flue gas spillage and reduced service life of the vent system.

  • Page 17: Domestic Hot Water

    Raypak heaters are high-recovery, low-mass heaters which are not subject to thermal shock. Raypak offers a full line of electronic sequencers that produce direct reset of heater water temperature. (Refer to the Controls section of the Raypak Catalog.)
  • Page 18 Potable Water and Space Heating CAUTION: When this heater is used for both potable water and space heating, observe the following to ensure proper operation. 1. All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water.
  • Page 19 MIXING VALVE Fig. 14: Single Pool Heater Application A thermostatically controlled mixing valve is used to mix the outlet water with the pool water. This mixed water is supplied as the inlet water to the pool heater. The proper configuration is shown in Fig. 15. The active element of the valve adjusts the mixing ratio to maintain the inlet water above 105°F.
  • Page 20 Heat exchang- er failure due to total dissolved solids in excess of 2,500 ppm is a non-warrantable condition. Raypak offers basic temperature guidelines for operation of a potable water heater on normal to moderate levels of...

  • Page 21: Gas Supply

    DANGER: Make sure the gas on which the heater will operate is the same type as specified on the heater’s rating plate. Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-off valve lo- cated outside the heater jacket.

  • Page 22: Electrical Power Connections

    6. Reinstall the pipe cap on the left-hand end of the main gas line. 7. Remove plastic cap from the right-hand side panel and reinstall into the standard main gas opening located on the left-hand side of the heater. 8. Remove the rubber grommet from the left-hand- side panel and reinstall into the standard main gas opening, located on the right-hand side of the heater.

  • Page 23: Field Wiring Connection

    Check the Power Source WARNING: Using a multi-meter, check the following voltages at the terminal block inside the unit. Make sure proper polarity is followed and house ground is proven. (See Fig. 18.) BLACK CIRCUIT BREAKER WHITE GREEN GROUND A B C Fig.
  • 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: Wiring Connections Installer action is required to electrically enable your heater to operate after making the power connections. You must make a closed contact connection on Stage 1 connector of the Central Point Wiring (CPW) board for temperature control connections.

  • Page 25: Venting

    SINGLE STAGE TANKSTAT STAGE 1 CONNECTION ATTACH STAGE 1 CONNECTIONS ON HEATER TO THE SINGLE STAGE TANKSTAT AS SHOWN IN THE DIAGRAM ABOVE. Fig. 23: Single-Stage Tankstat Consult the wiring diagram shipped with the heater in the instruction packet or at the end of this section. The stage-selector terminals are for the remote tank con- trol through the heater’s 24 VAC transformer.
  • Page 26 CAUTION: When condensate traps are installed, condensate must be routed to an appropriate container for neutralization before disposal, as required by local codes. WARNING: Contact the manufacturer of the vent material if there is any question about the appliance categorization and suitability of a vent material for application on a Category III or IV vent system.

  • Page 27: Changing The Flue Outlet

    8. Locate and guard vent termination to prevent acci- dental contact by people or pets. 9. DO NOT terminate vent in window well, stairwell, alcove, courtyard or other recessed area. 10. DO NOT terminate above any door, window, or gravity air intake. Condensate can freeze, causing ice formations.

  • Page 28: Venting Installation Tips

    5. Remove the screws, retaining ring and rain gasket from top of heater. 6. Remove the screws, flue collar and gasket from the run side of the tee located in the flue box on top of the heater. 7. Reverse the components and reattach in the new location.
  • Page 29 Termination The vent terminal should be vertical and should termi- nate outside the building at least 2 ft above the highest point of the roof that is within 10 ft. The vent cap should have a minimum clearance of 4 ft horizontally from and in no case above or below (unless a 4 ft hori- zontal distance is maintained) electric meters, gas meters, regulators and relief equipment.
  • Page 30 The direct vent cap must be installed at least 1 ft above ground level and above normal snow levels. The Raypak-approved stainless steel flue direct vent cap must be used (sales order option D-15).
  • Page 31 Certified Model Venting Material 302B 402B 502B Category III 652B 752B 902B * Subtract 10 ft per elbow. Max. 3 elbows. Maximum combustion air duct length terminated at 100 equivalent ft. Table O: Category III Horizontal and Direct Venting Use only the special gas vent pipes listed for use with Category III gas burning heaters, such as the AL29-4C stainless steel vents offered by Heat Fab Inc.
  • Page 32 For installations in extremely cold climate, it is re- quired that: 1. The vent must be installed with a slight upward slope of not more than 1/4 inch per foot of hori- zontal run to the vent terminal. In this case, an approved condensate trap must be installed per applicable codes.

  • Page 33: Controls

    Flues supported only by flashing and extended above the roof more than 5 ft should be securely guyed or braced to withstand snow and wind loads. The air inlet opening MUST be installed 1 ft above the roof line or above normal snow levels that might ob- struct combustion air flow.

  • Page 34: Heater Sequence Of Operations

    Fig. 28: Status LED Indicator Decal Heater Sequence of Operation Models 302B-902B 1. The black (hot) wire lead goes directly to the main power switch. This black toggle switch is located at the middle front of the control compartment. 2. When the main power switch is placed in the “ON” position, 120 VAC is applied to the 120 VAC termi- nal block on the circuit board and the 120/24 VAC transformer is powered.
  • Page 35 Light Power Call For Heat Safety Ignition Flow Blower 1 Stage 1 Stage 2 24. Power is also sent from pin 2 of the stage 1 con- nection to pin P1-3 of the universal diagnostic board. 25. Power is now sent to terminal TP4 of the Economaster to energize the relay and close the contacts.
  • Page 36 45. The stage 1 LED on the status display board is now illuminated. 46. The coil of relay K-2 is now energized with the N.O. contacts closing downstream of the stage 2 connections. 47. The gas coming through the burners should ignite from the heat of the hot surface igniter and the flame should carry over from one burner to the other burners of stage 1.

  • Page 37: High Limit

    High Limit (Manual Reset) The heater is equipped with a manual reset high limit temperature device. Push the reset button and adjust the setting to 40 - 50°F above desired operating tem- perature. Fig. 30: High Limit (Manual Reset) Flow Switch This dual-purpose control, mounted and wired in series with the main gas valve, shuts off heater in case of pump failure or low water flow.
  • Page 38 Fig. 34: Fan-Proving Switch Fig. 35: Blocked Vent Switch Pump Time Delay The Economaster is a fully enclosed solid state TDR with a white jumper that selects one of two time delays. See Fig. 36. If the jumper is on pins 6 and 7 (default) the delay time is 5 minutes.

  • Page 39: Udb Fault Messages

    Detection Hi Delta PVC Vent Limit-CHX Manual High Limit Auto High Limit Low Water Cut-off Vent Pressure Low Gas Pressure High Gas Pressure Controller Alarm Flow Switch Blower Switch Factory Option External Interlock CWS/CWR Ignition Lockout Field Interlock # Fault Flashes Low Air Flame - No CFH...

  • Page 40: 87%-Efficiency Boilers

    Fig. 15, must be piped into the system at the time of installation. This piping is like a primary/secondary boiler installation with a bypass in the secondary boiler piping. Raypak strongly recomm- 10°F T Model P (ft)
  • Page 41 WARNING: Contact the vent material manufacturer if there are any questions about the appliance category or suitability of a vent material for Category II, III or IV applications. Using improper venting materials can result in personal injury, death or property damage. Vent Terminal Location NOTE: During winter months check the vent cap and make sure no blockage occurs from build-up of...
  • Page 42 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. Horizontal Through-the-Wall Venting (Category IV) *Requires optional vent tee for rear discharge. Fig. 39: Horizontal Through-the-Wall Venting (Category IV) Installation These installations utilize the boiler-mounted blower to...
  • Page 43 The stainless steel direct vent cap must be furnished by the boiler manufacturer in accordance with its list- ing (sales order option D-15). Use only double-wall vent pipe and the special gas vent pipes listed for use with category II or IV gas burn- ing boilers, such as the stainless steel Saf-T vent by Heat Fab Inc.
  • Page 44 Direct Vent - Vertical Certified Model Venting Material 302B 402B 502B Category II or IV 652B 752B 902B * Vent lengths are based on a lateral length of 2 ft. Refer to the latest edition of the NFGC for further details. When vertical height exceeds 25 ft, consult factory prior to installation.

  • Page 45: Wiring Diagram

    Wiring Diagram...

  • Page 46: Start-Up

    NOTE: Boil-out information: The oils, grease and other contaminates found in some gas fired boilers are not present in the water side of a Raypak appliance. Most boil-out procedures require the use of an alkaline (high pH) cleaning agent that will damage the copper finned tubes of the heat exchanger.

  • Page 47: Start-Up

    Preparation WARNING: Do not turn on gas at this time. Check Power Supply With multi-meter at incoming power, check voltage between: Hot - Common (≈120 VAC) Hot - Ground (≈120 VAC) Common - Ground (< 1 VAC) WARNING: If Common - Ground is > 1 VAC, STOP: Contact electrician to correct ground failure.
  • Page 48 Safety Inspection 1. Check all thermostats and high limit settings. 2. During the following safety checks leave manome- ters hooked up, check and record. 3. If other gas-fired appliances in the room are on the same gas main, check all pressures on the Hi Delta with all other equipment running.
  • Page 49 1. Manually close the downstream leak test valve. 2. Open test point A and connect a manometer to it. Verify that there is gas pressure and that it is with- in the proper range (NOTE: must not exceed 14.0 in. WC). 3.

  • Page 50: Operation

    10. To restart system, follow lighting instructions in the Operation section. 11. Check to see that the high limit control is set above the design temperature requirements of the system. For multiple zones: Check to make sure the flow is adjusted as required in each zone.

  • Page 51: Troubleshooting

    TROUBLESHOOTING Does the power switch provide power to the control panel? Step 1 Step 2 Is Disable j um p er intact? ( J1 ) Do the combustion air Step 3 blowers come on? Step 4 Are the blower lights illuminated? Is 24VAC at PS on ignition module? Is...

  • Page 52: Maintenance

    MAINTENANCE Suggested Minimum Maintenance Schedule Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency. Maintenance as outlined below may be performed by the owner. Daily 1. Check that the area where the heater is installed is free from combustible materials, gasoline, and other flammable vapors and liquids.
  • Page 53 Weekly For low-pressure heaters, test low-water cut-off device. (With at least one stage of the appliance on, depress the low water cut-off test button, appliance should shut-off and ignition fault light should come on. Depress reset button to reset). Monthly 1.

  • Page 54: Appendix

    APPENDIX Inside Air Contamination All heaters experience some condensation during start-up. The condensate from flue gas is acidic. Combustion air can be contaminated by certain vapors in the air which raise the acidity of the condensate. Higher acidity levels attack many materials including stainless steel, which is commonly used in high effi- ciency systems.
  • Page 55 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 56 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 Wa rranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but a re the owner’s responsibility.
  • Page 57 START-UP CHECKLIST FOR FAN-ASSISTED This start-up checklist is to be completely filled out by the service technician starting up the Raypak Boiler or Heater for the first time. All information may be used for warranty purposes and to ensure that the installation is correct.

  • Page 58: Important Instructions For The

    The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through – the – wall vented gas appliances as follows: (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet...
  • Page 60 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.

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Hi delta 902b

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